Structural building element



March 23, 1954 H. L. PIERCE STRUCTURAL BUILDING ELEMENT Filed Nov. 26, 1946 2 Sheets-Sheet l INVENTOR. 4. 1 /5205 fizzo r72 6 March 1954 H. L. PIERCE STRUCTURAL BUILDING ELEMENT 2 Sheets-Sheet 2 Filed Nov. 26, 1946 INVENTOR. BY 14412040 1. 1 /6266 III/III Patented Mar. 23, 1954 UNITED STATES PATENT OFFICE 2,672,958 STRUCTURAL BUILDING ELEMENT Harold L. Pierce, Pasadena, Calif. Application November 26, 1946, Serial No. 712,453

3 Claims.

My invention relates to structural panels, and has particular reference to a panel construction permitting interlocking of the panels to form a solid surface for use as a floor, ceiling, wall or other structural element.

While my invention has general utility, I will describe it with reference to its presently utilized embodiment; namely, as applied to double wafllelike panels formed of sheet metal. These wafiielike panels may be formed of two sheets of metal, each having a regular pattern of square projections formed thereon in a general wafile form. .The two sheets may be placed back-to-back by disposing the flats of the waffle pattern of each sheet in contact with each other, and spot welds may be formed on the flats to secure the two sheets together. I

Such waflle-like sheets are characterized by extremely high strength, together with lightness in weight. For example, when such a panel is made out of #26 sheet steel and each sheet is dished about one-half of an inch so that the overall thickness is about one inch, a panel a foot or two square will have sufiicient strength to act as a floor member and at the same time will have a weight of approximately a pound and a half per square foot. Accordingly, therefore, these wafllelike panels are capable of use as any solid structural member of a building, such as floor, ceiling, roof, or side walls, or special forms may be employed as posts, columns, pilasters, etc. Plaster or cement may be applied to the panel, and in this connection various of the projections of the waflle-like form may be apertured so as to permit a grip by the plaster or cement thereon. In'general my invention embodies the formation of flanges on elongated panels, which flanges are disposed approximately at right angles to the plane of the panel. The edge of one flange of the panel may be bent back upon itself to form a general hook cross section, which hook structure may receive a straight-sided flange of an adjacent panel. My invention further embodies the use of fastening members to hold adjoining flanges either with or without the hook interlock. Also my invention makes possible the joining together of panels in unique and special forms so as to form new structural elements for buildings, which elements also form a part of my invention.

It is therefore an object of my invention to provide an improved locking or joining structure for panels. v

Another object of my invention is to provide panels with flanges having hooked edges adapted to receive straight wall flanges of adjacent panels.

Another object of my invention is to provide flanges for sheet metal waffle-like panels, which flanges may be used as joists or other framing equivalents for a building.

Another object of my invention is to provide a fastening structure for structural panels used as roof members, which structure incorporates a waterproofing element.

Still another object of my invention is to provide a method and means of joining thin structural members together to define columns, posts. ridges or other framing elements of high strength, particularly when the space defined by the elements is filled with concrete or other high strength material.

These and other objects and advantages of my invention will be apparent in the following description and claims, considered together with the accompanying drawings forming an integral part of this specification, and in which Fig. l is an isometric view of a corner of a building structure formed of panels and other structural elements embodying my invention;

Fig. 2 is a perspective view of an embodiment of my invention as applied to a joint between two adjacent panels such as might be used in the structural building of Fig. 1 as viewed along the line IIII of Fig. 1;

Fig. 3 is an elevation sectional view of a joint between two panels used for roof members and incorporating a waterproofing strip or element;

Fig. 4 is a second modification of my invention as applied to thin structural members that define a shaft that may be filled with concrete or other material to form a high-strength post or column as viewed along the line IV-IV of Fig. 1;

Fig. 5 is an elevation view of one form of fastening device that may beemployed to retain the panels of my invention against a concrete subfioor or other solid surface as viewed along the line VV of Fig. 1;

Fig. 6 is still another modification of my invention showing its employment for use with structures that define a ridge or equivalent element for a roof structure;

Fig. 7 is a detail sectional view of the panel fastening of the roof structure of Fig. 6 taken along the line VIIVII of Fig. 6

Fig. 8 is a sectional view along the eaves por tion of a roof structure showing a cap construction for defining the eave and Fig.9 is a sectional View through a double wall structure including panels secured together in accordance with the invention, as well as a rounded corner-piece, for example, as used in a refrigerator.

There is illustrated in Fig. 1 a plurality of uses to which the panels may be put that embody my invention. For example, a structure may include a subfloor it formed of concrete or other materialupon which may be disposed a plurality of elongated. panels il joined at their edges in accordance with the invention. The structure may also include a plurality of posts 52 which may be formed of the usual structural steel, wood or other material, or the postsmay. particularly in accordance with theinvention as in the case of the post It. Girders M may interconnect the four posts mediate bracing girder 16 may be utilized as an intermediate framing member. rest upon these framinggirders and these panels maybe used either as afloorfor a second story of the building, or as a roof surface. Panelsim corporating my invention may also be used as external wall members as illustrated by an upright" elongated panel-member I8. Accordingly, therefore, Fig. l discloses various uses of panels which-,may incorporate my invention, and this illustrative-showing is primarily for the purpose of indicating thatrny'invention may be employed in a great entire structural buildingindustry.

Thereis illustrated in Fig. 22. representative typeof waffle-like panel structurethat embodies my, invention. For example, Fig; l may berepresented by the disclosure-of Fig. 2 wherein it will be noted that the panels employ a plurality of .projections ifi joined-together by flats 2,! and that theflats or" two oppositely disposed weldeditogether as at Various of the projections l9 may be apertured as at 2'3-"ior the reception of plaster. or concrete or other covering material so as to obtain a goodbond or adher ence of" the covering materialto the panels H; Each panel H may be provided with a downwardly projecting flange M made particularly in accordance with the invention andwhich flange, may be provided with a waffle-like structure 2'6 on at least one surfacethereof. In this connection it should be noted that the angular bend.t0,.form thefiange is constructedof spaced sheet metal portions 2? and 21a to maintain the strengthof the joint approximately the same as the overall strength of the waffle-like paneling.

Thebottom edge of one of the flanges it may be. formed into a generallhook shape 2%, and the, bottom. edge of. the other panel may be straight and fitted in the hook portion. In this connection. it should be noted thaton any one panel only one flange generally has a hook formed thereon, the other flange being straight sothat' the edges of two adjoining panels may be joined by the hook and straight. portions thereof. The lower. edges of the panels thus joinedmay. be of asingl'e thickness ofmetal, or where desired may be of double thickness,,but in this event it is preferable to stop the waii'lelike form a short distance fromthe bottom thereoff, The two flanges may be secured together in p as by aplurality of a variety of fashions, such bolts 28 withnuts 291' threaded thereto. Alternative1y,.the. panels may be secured together. in addition to the jointstructure 21. by. means of bendable, ear portions. 31 formed in the. bottom be. formed.v

i2 and it, and. an inter- Panels" l'l may variety of places and locations in the the panels H of sheetmetalsections may be spot ill of each flange 24 so that the ears will be disposed opposite to each other. These ears may be bent together as shown at 3la to crimp the two panel members together.

The bottom edge or hook 21 of the two joined panels may bear against the supporting surface such as a concrete sub-floor as shown in Fig. i. If desired, however, the entire panel structure may be spaced from the fioor, or other main support by means ofrods .32 thattmay pass through the reinforced or waiil'e-like portions of the flanges 24, the rods in turn being supported above the sub-floor It in any suitable manner (not shown): such as by means of supporting beams, supporting posts or the like which may bedisposedon sub-floor l0.

Therpanel' structures may be secured against movement upwardly by means of rods 33 that may pass through the lower portions of the flanges 24, and in this connection it will be noted that. the'rods: 33 also aid intying together the panels. Hooks-flzmaybe passed around the rods was shownzin Figs. 1 and'5; and may. in turn be tied down to suitable members such asangle irons 35 which in turn may be held-to the subfloor iiliby bolts -36' embeddcd in concrete.

It. willibe noted with respectto Fig. 2 that the major part of the flanges 25- may contain the waffle-like formation; thus" giving them great strength with-respect to bending and crumpling. Accordinglythe flanges-a 24, particularly when joined together, form a very strong and solid structural member thatv is akin to=a-joist for supporting floor structure; Panels constructed in accordance with my invention therefore may serve. as a .complete flooring structure,- including joists and planar spacing materialbetween the joists;

A modifiedformofi'my invention is illustrated in Fig 3, wherein. the flange hook structure'is aidedin locking the panels together by'a circular depression running lengthwise of the panel flange. This type of joint may be used with roof panels, and in. this event awaterproofing T elementmay be disposed between the flanges.

Accordingly 'two roofipanelsAfl formed of wailielike or other high-strength sheet metal'may have flanges Mformed thereon; each of :which may be formed with a longitudinally extending ribor circular depression 42; The alternate-flanges of the panel members. it: may be formed with ahook portion 43 into which the-straight flange of, the adjoining panel. lifl'mayflt.v The mating ribs of the two flanges secure the panels: from slipping out of their. hook joint. This joint may also; be usedz to receive mastic or: other pliable material 44 which may bedisposed as a. strip againstoneof the flangesdil beforerthe flanges are'assembled. This materialisadapted to maintain its flexibility. and adhesive characteristic :for a number-0f years, thus moreaor; lesspermanently sealingthe crackbetweenthe; two flanges-M. This effectively, sealsv the joined roof panels, particularly: when. a covering coating of; cement, plaster or asphalt is laid upon the tops of the panels-Inland also the jointibetween them.

Shown in Fig, 4 is. a modifiedformbr my invention as applied to. an integrali column structure, adaptedto -be filled with; concrete or. other stiffening material to form the column l3 (Fig. l). Accordingly.-a.waffle,-like member. id-bent in general. right angle form may be secured by welding or otherwise to a complementary waflie-like portion 4.! bent; attan opposite, right. angle so that .the two define a generally square. chamber insulation are of importance.

48. The two members 46 and 41 may have considerable height and thus define'an elongated shaft 48 which may be filled with concrete 50 to form a structural column. Flanges 49 may be formed on the edges of the two joined-elements 46 and 41, and may have hook portions 5| formed thereon adapted to receive the side panels l8 or other structural panels. Accordingly, therefore, an entire story of a building may be enclosed and defined by panels connected together in accordance with the invention and the corner members thereof may be in hollow columnar form, which hollow column may be filled with concrete, either reinforced or plain.

Shown in Fig. 6 is an application of my invention to a ridge-board structure for a roof. Roof panels 52 may have their edges bent into flanges 53,the angle of the flanges with respect to the panels depending upon the slope of the roof. A generally triangular element 54, made of wafllelike or otherwise, may have its two edges 56 brought together and elongated on their outer ends as at 51. The entire triangular element 54 may be filled with concrete 58, thereby making an extremely rigid ridge-board for the roof. The fastening of the panel flanges 53 to the edges 56 may be accomplished by means of through-bolts 59 having an eye 6| formed on the head end thereof. Rods 62 may be passed through the aligned eyes of the various bolts to keep them from rotating when nuts 63 are tightened on the opposite ends of the bolts. This joint structure of the flanges to the ridge-board member 54 may be more rigid if the edges of the panel flanges 53 are rolled, as shown in Fig. 6.

The entire roof panel structure 52 and the ridge-board 54 may be covered with a suitable weather-resisting material, such as cement or composition material 64'. Since the waflle-like panels 52 are generally formed of steel because of cost considerations, it is accordingly imperative that the edges of the panels 52 be encased with a non-corrosive eave structure. Accordingly, as shown in Fig. 8, a generally channel-shaped eave member 66 may be riveted or otherwise secured to the outer edge of the roof panels 52, and preferably a strip of mastic 61 is placed on the inner side of the channel-shaped member 66. The undersurface of the roof panel 52 may be covered with a spaced sheet of metal 55 and, the space between the two members may be filled with insulation or cement, as desired. The undersheet 55 and the eave cap 66 are preferably formed of a non-corrosive material, such as aluminum.

Illustrated in Fig. 9 is a modification of my invention which is suitable for double wall structures such as refrigerator cabinets. Accordingly panels H of any suitable construction may be formed with flanges 12, the opposite flanges being formed with hook members 13. Also alternate flanges 12 may be formed with cars 14 that are parallel to the main body of the panel H. The various panels Il may be joined together as gen erally described with respect to Fig; 3, and may also include a strip 16 of mastic or insulating material where waterproofing characteristics or An inner wall 1! may be secured to the ears 14, and the space between the inner wall 11 and the panel 1| may be filled with insulation if this is desired. A corner construction also made in accordance with the invention may be employed on cabinet structures, and may include a generally arcuate surface 18 which may be reinforced if desired by a generally angular internal structure 19. The

corner structure may include flange members 8'!- having bulges 82 formed therein. One flange 8| may slide within the hook element 13 of a panel 1| on one corner, and the other flange 8| may abut against an unhooked flange 12 of another panel member 1|. If desired, a corner bracket 83 may secure the corner assembly together and screws may be used to secure all flanges together. The corner member 18 may be extruded or fabricated as desired, and may be of metal, plastic, or other easily worked material.

From the foregoing it will be evident that my invention provides a fastening construction-for panels and corner members that is simply made and at the same time rugged in construction. Also the'fasteners are easily assembled, making possible the use of unskilled labor in assembling buildings made of panels with my fastening devices. It is obvious that various types of materials may be used in my invention, and while I prefer metals, it is apparent that plastic or other material could be used. Accordingly I do not care to limit myself to the specific embodiments and materials illustrated and described, nor otherwise, except by the terms of the following claims.

I claim:

1. A building panel structure including a pair of building elements, each of which comprises a flat panel formed of two sheets of metal having a waffle-like structure formed thereon which are secured together, and a flanged edge on each of said panels directed generally at right angles to the flat portion of said panel and including portions of both of said two sheets of metal, the flange portion of one sheet being flat and facing generally outwardly away from said panel, and the flange portion of the other sheet being of waflle-like construction and facing generally inwardly toward said panel, said pair of building elements being secured together with their respective said flat flange portions disposed adjacent to each other so that said flanged edges of said panels form a joist.

2. A building panel structure including a pair of building elements, each of which comprises a flat panel formed of two sheets of metal having a waflie-like structure formed thereon which are secured together, a flanged edge on each of said panels directed generally at right angles to the flat portion of said panel and including portions of both of said two sheets of metal, the flange portion of one sheet being flat and facing generally outwardly away from said panel, and the flange portion of the other sheet being of waflielike construction and facing generally inwardly toward said panel, said pair of building elements being secured together with their respective said flat flange portions disposed adjacent to each other so that said flanged edges of said panels form a joist, and a plurality of rods passing through said flanged edges of said panels supporting the panels and holding them in aligned relationship.

3. A building panel structure including a pair of building elements, each of which comprises a generally horizontally disposed, flat panel formed of two sheets of metal having a wafile-like structure formed thereon which are secured together, a flanged edge on each of said panels directed generally downwardly and at right angles to the flat portion of said panel and including portions of both of said two sheets of metal, the flange portion of one sheet being flat and facing generally outwardly away from said panel, and the ammalsa flangergortionroi: the other sheetbeing' of waffieelike. construction. and facing? generally inwardly towardsaidmanel, said pair oibuilding; elements being: secured together with their respective said flat"; flange, portions disposed: adjacent to: each other so that said flanged edges of said, panels forma" joist, and an upwardly directed hook structure'formed on the bottom portion of one oil said downwardly flanged edges gripping: the other of said: downwardly flanged edges-..

HAROLD L; PIERCE.

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